engine work on the old honda 250 trials bike,

Hi guys, in this video l go over why l did what l did then get into setting up the engine,repair the exhaust,rebuild the carb, and make some missing parts,

[@richardcreaser308]

Hi Mustie, I originate from the UK, I am now retired & living in Thailand. My background is in aero engineering but I was bitten by the motorcycle ‘bug’ long ago. Until I moved to Bangkok, I spent my spare time restoring old motorcycles. It gives me so much pleasure to watch your videos. My main weakness was painting. I restored a 1955, 350 BSA & decided to have a go at painting it myself but I did have the fuel tank professionally painted. I used an engineering paint, made by a company called Blackfriars, but it’s main drawback was a long drying time & white spirit as a thinner. I didn’t have a spray booth - I got chucked out of the wife’s laundry shed for getting overspray on everything. I sprayed it outside on nice days. Trouble was it seemed to attract bugs. So many times I had to remove the paint & start over. After I sold it, the man who bought it sold it on but one day I got a phone call from the new owner. He told me that he had entered it into a concours exhibition & it won second prize. He said that the judges were impressed by the paint work because it didn’t have that hard ‘glassy’ look to it, which made it look as if it had it’s original paint. It’s main let down point was the fuel tank that was black with silver panels on each side, the silver should have been chrome! He wanted to know what other parts were not original so that he could make it fully original for future shows.

[@spaceinvadertoo]

You repair of the exhaust pipe flange fitment and the air box cover really demonstrates the value of your metal working knowledge and experience. I'm impressed.

[@sreekumarUSA]

Hats off to you. Such tremendous amount of hard work on Mechanical side, plus you gotta film the process, decide certain critical designs on the spot etc etc.... I can imagine how hard must be your Central Nervous System working ! Above all... this is a one man show, no one around you to lift a finger.. and the result, so flawless and some times better than the manufacturer. Watching, some times, several episodes at a stretch; I feel the Clock is Warp Speed ! To be so honest, I have seen the East in Crimson. Cheers.

[@robertbiggs4934]

Awesome job on the exhaust flange! You are truly a mechanic...not just a "remove and replace" artist. You actually repair "stuff". Love your work. Thanks for letting us be a part of the project...and helping YOU talk your way through!

[@hene193]

I like how the outside condition is little rough but the mechanics is top notch! It seems like a good bike.

[@ronrice3769]

After a lifetime in the trades I am able to do little else now but watch. That said I sometimes have a little trick to share and I think you will use them. Here's one. When cutting ,drilling or milling aluminum get a spray bottle of denatured alcohol as a cutting fluid . This keeps the metal from galling by keeping it very cool. You'll find it leaves almost a polished finish.

[@CTmoog]

The master fabricator at work. Always a pleasure to watch sir!

[@5150mxVW]

ahhhh , the sheer enjoyment of removing the rear axle on a vintage bike that hasn't seen grease since Japan ! Nice job on the air box lid fab .

[@alecjahn]

I experienced that joy just a couple months ago (Trail 70 with 700 miles). It was also very nice to have a nice hot garage to work in.

[@petersmith6423]

Watching Mustie use a panel beating hammer for actual panel beating.... Phew!!!!!

[@jonnoMoto]

nothing compared to the stinky whale oil in the forks on vintage japanese bikes. wretch-inducing.

[@deborahchesser7375]

@@jonnoMoto I remember that fish oil, that’s crazy. Then again, it was when we ran still ran bean oil, no synthetic back then.

[@dalesubic345]

I taught electronics troubleshooting and calibration in the Navy. I can only imagine how much you have learned doing these videos. I learned more as an instructor for 3 yrs than I did in 6 yrs as a tech. Thanks for what you do. There are people out there that know a lot but, there are a lot of back seat drivers too.

[@thomasboulay3309]

Very nice metal work with the flange and the cover! My dad had the gift, I saw him straighten a Model A headlight bucket with a decent dent in it and make it look like new. Couldn't even tell where the dent was! Thank you for the great videos, I really enjoy them!

[@essexviewer]

I’ve been mucking around with small motors for years and I have to tell you that I learnt more about carbs and valves in the time since I found your channel than i have in twenty years of guessing! Thank you!!

[@BobPegram]

But that leaves a big question: Where did Darren learn all of this? Maybe "Mustie1 our mechanical genius" figured it out for himself!

[@andymck6323]

me too

[@MrWoolyMonster]

I have l

[@maxhammontree3169]

Sometimes I feel like I’m watching myself work. We do so much stuff the the same way. Love it!

[@pontiacgrandprix733]

Gotta tell you, the self control you use, in not over restoring things is the reason why you have so many toys, I would've been on EBay and probably bought an entire air box, cause I couldn't make a cover, God bless you have gold in your hands

[@daza3620]

Watching your videos gave me the confidence to replace the wheel bearings on my Honda motorcycle today. thank you.

[@jlucasound]

I think you are the pioneer of "fast forward". I love watching that. Just like watching "driving" in real time, down a road I never rode down.

[@bobferranti5222]

Mustie, I was going to suggest you use anerobic sealer on the rocker cover in the last video but forgot to mention it after watching. It will only harden where the surfaces meet, otherwise it stays soft and wont clog anything. I use it on supercharger assemblies because it stays soft when it squeezes out and wont damage anything if it comes in contact with the internals. That was some impressive flange making!

[@katzfam1089]

Thank you for allowing us into your garage.

[@mustie1]

thanks for watching katz

[@Mrcaffinebean]

Thank you for explaining your thinking on what you didn't do. It helps us new guys learn to do stuff right.

[@jeanclaudevandam4974]

He gets better and better every video since the first. Also Mustie is becoming a great camera man and editor. All around very talented man. Thanks for the videos.

[@jlucasound]

What you said. I can't even add as you have covered it all. Thank You for sharing your wrenching. You are one of the best.

[@garypaisley]

Nice work! I owned a new TL250 in 1976, sold it to a deer hunter in Denver in 1986. Good bikes, although a bit heavy for trials, make great trail bikes.

[@kevinl8350]

I like how he actually fixes things and doesn’t just throw money at it

[@MrUbiquitousTech]

And still does a proper repair. Showing that money's not always the answer.

[@Maxxarcade]

It was cool (and funny) watching the exhaust pipe slowly morph with the sped-up hammering. The fabrications turned out great!

[@wi11y1960]

Oh great happiness! A hour with Mustie! Hondas in the 1980s used a cream that you let firm before assembling. Learned this from a friend I had in California when I had a similar bike. Honda informed me that you are to put a drop or two of oil directly to the wick lubricator for the points.

[@mikebaird3867]

Watching your videos inspire me to get back into wrenching, no matter how tired I am from work, thanks

[@michaeljcoulter]

The last engine (outside of work) I worked on was a little 2.5cc nitro car engine. These videos have made me want to buy an old bike just to tinker with!

[@markchatman9583]

When you’re tapping out the axle it helps to put a piece of hose on your brass rod to keep it central on the shaft. And the brass rod just pushes right through

[@beakittelscherz5419]

...sometimes I just don´t know if you guys still talking about motor adjustments...Lmao

[@jtp336]

I love your vids man, especially the Honda ones. Im in the process of restoring a 1952 Honda Dream E-type, watching what you do gives me the confidence to tackle it.

[@chetleonard169]

I was skeptical about the blacksmithing idea, but you did it! Impressive.

[@red88ization]

the flange repair was very well done

[@n1r0lanynonmouse6]

At 27 minute mark, his hammering was really fast!! If my hands were that quick, my wife would never let me out of bed.

[@kragecraig5017]

You packed a lot of lessons in to this one. Great video.

[@leemer1]

A trick I learned for adjusting valves with those square adjusters is simply screw a #2 Robertson screw into a small wooden dowel and there ya have a holder for that square adjuster.

[@cencalmatt]

I don't comment much but just wanna say you've inspired me. Not to be a downer but I never had a dad to teach me this kind of stuff and I find myself wanting to tinker and learn about it! Thanks.

[@floydloonie4880]

Excellent project that is inspiring me to finish a 1963 Honda 90 CL that I put together back in the late '80s and never felt the need to complete, as I was riding a HD Sportster back then & 1200s later, but now that I'm old and busted up, I might pull it out of the shed and get 'er done finally. Hmmmm?? Thank you for sharing this video.

[@txnetcop]

Best on-the-go fabrication job I have ever seen!

[@muskokamike127]

When you were forming the air box cover, a neat trick I learned from a metal worker: a foam seated bar stool. Put your piece into the middle of the stool seat and pound on it in the middle. It will draw the piece out where you hit it. I saw Jessie James do a fuel tank this way without using an English wheel. I've tried it a couple of times, works great!

[@wi11y1960]

Sand bag will also work

[@muskokamike127]

Yeah I've seen that done too...just don't over stuff it, you want the sand to be able to move so the metal conforms to the strike.

[@HUBBABUBBADOOPYDOOP]

If the metal is heated- it stretches nicely, too.

[@muskokamike127]

and if you want to shrink it, dump ice cold water on it while it's hot......

[@HUBBABUBBADOOPYDOOP]

Wouldn't a shock quench like that HARDEN it, make it brittle?

[@n2n8sda]

You are right on those timing marks.. the T mark is top dead centre (The line at the bottom is the mark) and the F is for the firing mark (BTDC)... :)

[@throttlebottle5906]

every honderp bike made that I know of :)

[@masm60]

Your exhaust flange is a work of art.

[@deborahchesser7375]

Cool job on the air box , that’s where we find out who really is resourceful and talented.

[@Jim-ie6uf]

Without a doubt one of, if not the finest video I’ve ever seen. A mix of you “live”, Hand Tool Rescue, and Retro Hacks. This must have been a compilation of a weeks work. Darrin, you are amazing!

[@zsolthajdu5007]

If my copper seal rings are a bit too small, i get a punch or something that's cylindrical, put it inside the ring and roll it on a steel plate under hand pressure. Basically stretching it a little all the way around. Works for me. Love your channel btw, i work on old American cars in Europe.

[@Melw44]

Always fun to watch you fab up missing parts.

[@buttguy]

The donut-style spoke wrenches that have like 8 or 10 different size slots on them are perfect for holding onto motorcycle valves while adjusting the locknuts. Thats what i always used on my SR500.

[@danmackintosh6325]

This is an excellent piece of advice, nice call.

[@joelmollenkopf3767]

Excellent I really enjoyed what you did to the exhaust pipe never thought of that fix!!

[@stanRmeyer]

joel mollenkopf same here muski grayed out of the box fix

[@johnmaggs769]

Well I didn't see that coming, what a great way to make a new flange. two thumbs up.

[@rhysjones4988]

Great video as always! I understand why you speed up repetitive work, but I would appreciate subtitles for the high speed commentary if at all possible. I bought a broken 1965 Honda C110 (50 cc)at age 13 in 1971 for $100. It was completely dissasembled and Honda had stopped making shop manuals for it. Eventually I figured out that the exhaust valve was slightly bent. I tapped it lightly until it was straight as tested in a drill. After using compound to seat the valve and enlarging the exhaust port to match the pipe, a smaller friend hit 62 mph on it. It's 4 speeds, a clutch, and 17 inch wheels were lots of fun. Looking back, I'm glad nobody ever got hurt riding it. My rule was, if you wanted to ride it, you had to wear ear a helmet.

[@rogerandlyndabeall3840]

I had a C-110 too!

[@MMR45660]

Amazing jury rigging and retrofitting. Great job. Love the soothing ending as well.

[@DamonBates]

Mad skills, mad skills. What a series. Thank you.

[@richardwarnock2789]

YES it's MUSTIE ONE in the Morning!!!!,Nice Fabricobbiling work !! Enjoyed the whole morning thanks !!!!

[@samfallow18]

Some great metal work skills on display. Good job.

[@PuchMaxi]

No flange? No problem. No air cleaner cover, also not a problem. Very impressive, Mustie1 is a good fabricator!

[@esqueue]

I was piloting Air Force 1 but I got a notification of a Mustie1 video. Mission is on standby for 1 hour.

[@swisherswish1072]

Lol 😂 😂

[@wi11y1960]

Trump wont mind, he will just revoke your security clearance.

[@ColtSSR]

I was in the middle of a brain surgery operation and I just let the temp finish up when I heard there was a new video.

[@davidthehillbilly7995]

I was about to get laid when my notification arrived. Oh well. She'll be in the mood again in another 3 or 4 years....

[@knighthawk86855]

Swisher Swish I was elbow deep in a 360 and I got the message head went up banged it on the hood release..... LMAO

[@gepettoe]

Love your videos. I know I can always count on them being real and truthful. Just watched a metal detector find a huge silver coin. you could tell it was a setup and the dirt had been previously pressed onto the coin.

[@straightpipec6099]

Very nice and cool! I agree that restoration is not necessary.

[@bryanjohnson7508]

I was so glad to hear you call it an engine instead of a motor

[@jbosem]

This whole series is making me really want a bike to ride the woods with

[@carlzrx]

Love the explanations as you go,very educational,you give us all the answers to our dumb questions we’re dieing to ask

[@kthwkr]

I think another way to look at is the hose on the compression tester was essentially changing the compression ratio.

[@biglakewheeler]

Great video mustie. I like the metal fabrication videos. Love to see more on the double cab repairs. Crazy all the equipment you’ve got in your garage. I just recently got a band saw for some bird house projects I’ve been wanting to do.

[@dwest320]

I'am still new here and every episode I watch is better than the last.

[@tomhallberg1285]

Flange repair/creation on the old header piper was top notch.

[@graemeduckett7576]

with any stuck valve its sensible to remove the cylinder head and check out the valve stem,,seat and guides for corrosion.Good time to fit new valve stem seals if it has them. 9 times out of 10 the valve seats spotty with rust,and the stem needs a good clean.Guides need a good look over and clean, Lap the valves in by hand and its away again.Check the play in the piston and check the lip at the top of the bore which is a good clue for blow by. Enjoy your videos,cheers Graeme from New Zealand

[@edgmp]

I haven't worked on a Honda bike since a year or two before that bike was born. Sure took me back! I still have the requisite impact driver, but I've upgraded my hammer. :)

[@Ejrupolsen]

You sir is a master drummer. 😉. and what a great comeback for the honda. 😊👍👍

[@raylouis]

Always fun hanging out at the shop. Keep Up The Good Work.

[@robertslinger5119]

The XL Airbox is a different shape I believe because XLs had a battery in that area strapped onto the side of the box behind the opposite side cover. The edges of the original TL airbox side cover (I had a TL125, but yours looks similar) was rounded so that the edge fits into the groove in the neoprene gasket, so when you tighten it on it is completely watertight. That way the only water ingress point is the inlet which is at roughly the same height as the tailpipe. That way you could ride a TL through a river pretty well up to height of tailpipe without water getting in the carb. I rode TLs in very wet trials in the 70s & passed many a Bultaco knocked out by deep river sections.

[@Tpklmale]

Came for high-speed hammering. Didn't leave disappointed! 5 stars.

[@steelwheels327]

You sir are a master mechanic . What is your background & you definitely would be a great teacher ..smart & patient !!

[@onemat2000]

Love the hammer and torch segment. The Buddy Rich of the hammer!

[@chrisclark4813]

Totally brilliant video. Thank you so much for letting me hang out in your shop.

[@RTDragonCommando]

I used to have a 1981 XL125S, before that I had an XL75 from 1977. Watching these makes me regret letting them go even more than I already did lol. I did a lot of work on the XL/XR engines, and that looks like the design they evolved from, a lot is very similar. I'd bet you could put an XR or XL 250 engine right into that frame with no fab work. I still remember the valve lash for those engines, and it might be the same for that engine, 40 thou on the exhaust and 30 thou on the intake.

[@vettekid3326]

What I have done to replace a cover seal like that is to slit a piece of vacuum line and use some weather striping adhesive to hold it in place.

[@kencollmar7868]

love watching your videos i like working on old hondas as well lil trick i learned take a square head drywall screw heat it up bend it over fits those valve adjustment screws makes adjusting them easy keep those videos coming !

[@clauslundberg9224]

Every tech thinks it - you bring words to it (which is great help to backyard guys like me) - thanks M1 for sharing

[@rogerfern392]

Another great video Mustie, it's always good to see old stuff being brought back to life... I'm currently renovating a 1977 CB 750 F2 and scour the Internet for ideas... Stumbled across your videos when you bought the CB 350 T, and I've been hooked ever since... Keep up the great work. Roger (Gloucester England)

[@DoRC]

14:00 its rare to see someone put the right amount of gasket maker on. Looks good!

[@geoffreyjones2000]

you mean very rare peace

[@Ludwig4571]

Would you happen to know what he is using in that squeeze tube? Find it anywhere?

[@Buck1954]

I am amazed at how you reflanged the end of the exhaust pipe. Your the faster hammer in the east.

[@ZPDSurvival]

You are a metal Drummer. LOL. I was going to say the same thing. I am working on the Honda SL250SE motor now. Your videos are helping me a lot. Thank You.

[@zx8401ztv]

Amazing how you work metal mustie1, the rim reform and airbox cover, both perfectly fine :-D

[@mantroid]

I've been trying to decide if my favorite tool is your tappy-tappy hammer, or your little fuel bottle.

[@wi11y1960]

Definately the body hammer

[@GettingNervous]

Both are absolutely necessary in every workshop ;-)

[@geoffreyjones2000]

I gotta say the fuel bottle with cam 2...purple

[@richardscott1397]

It's the body hammer. He uses that on everything.

[@jensu6932]

Fuel bottle!

[@jlucasound]

Ladies and Gentlemen, always use a softer metal rod (Brass) to hammer out something threaded and steel. Otherwise you will "Mung" the threads. @41:24, Mustie1 (off camera) was bashing down the "Mushrooming" of the brass rod so it would fit the bore of the bearing. The brass is what you would call "sacrificial". Don't use a steel rod to do this. I hope I am not stepping on Mustie's toes. :-) Great work sir.

[@alexfaetz9331]

Cheers for your knowledge im hooked Alex from the uk appreciate your patient presentation. Thanks!

[@mustie1]

thanks for watching

[@MrShrabber]

no need to explain you did what any other skilled tech would do common sense... Good work !!!

[@Chef_PC]

Well my morning just took a dramatic turn toward the lazy! Great timing, Mustie! I was looking for a reason not to work today...

[@fredflintstone2914]

In the 70's my friend had a TL125. Nice bike.

[@robertalgieri1968]

Another good watch very informative loved the exhibit fix

[@metaalateliermetal]

Niice tube forging job! Yelow works better then red hot, structure of your metal is less stretched that way.

[@epj900]

Brilliant idea, cutting and peening over the end of the exhaust pipe

[@kenfrazier616]

one slick idea peening the exhaust pipe, outstanding

[@georgemiller9314]

When you were heating /bending the exhaust, I was yelling (Put the flange on). Great Video !

[@martinconzemius5351]

Making that flange on the exhaust pipe was genius!

[@planetrob555]

Excellent job cobbling that flange!

[@graymodeler]

A leak down is used on aircraft cylinders since they can crack and lose power. I looked for about 78/80 to show a good cylinder. If not, listening at the intake, exhaust, and breather would pinpoint the leak. Friend of mine had an O235 Lycoming with a hole in the head casting.

[@sdhlkfhalkjgd]

A good "get ya by" trick for copper gaskets is to anneal them before re-using them. Copper easily work hardens, but if you heat it up with a torch and let it slowly cool it'll soften up a bit and give you a better chance of it resealing. Not too sure if the exhaust would't effectively do that anyway.

[@throttlebottle5906]

copper is pretty tough to anneal well.

[@sdhlkfhalkjgd]

throttle bottle - Yeah, better to use a new seal, but if you've got no other choice it can help. We were trained to do it on HPAC seals in the Navy. (Ebay doesn't ship to submerged vessels :)

[@throttlebottle5906]

they probably do now or will soon!! :)))

[@mikeshobbiesandrandomstuff]

The best gasket kits to order for the old Honda's is Vesrah they made the OEM ones back in the day.

[@geoffreyjones2000]

and the brakes peace

[@michaeljbaker3492]

Great video as always! Watching you work on these old hondas is great ! Cant wait to see the next one :)

[@alecjahn]

Lots of good wisdom and such in this one, Mustie. Thanks!

[@mohsenkiae5462]

😍 nothing more surprising than a notification from Mustie1 channel 😁 brilliant repair Darren 👍👏👏👏👏

[@Patiboke]

Love how you fixed the exhaust! Also nice to hear you rambling, one learns from it.

[@captnmike597]

The air box lid fabrication was terrific but I never even knew you could put a flange on a pipe the way you did that exhaust.

[@dave1135]

I have a matco compression tester I've had for 25 years, it looks like the one you have, except there is a short hose that screws into the spark plug hole and a adapter for long thread motorcycle style spark plugs. I never had a problem with mine. My check valve was on the guage also and the hose was wide open, and it fits my air hose Chuck at the shops I worked at. I would use it to hold valves closed while replacing valve stem seals on the car.